3500-Ton Press Main Frame Crack Repair Without Welding Using Metal Stitching

Imagine running a major automotive plant in North India where vehicle doors and bonnets are stamped out every single day. Now, imagine the heart of that entire operation—a massive 3500-ton press supplied by a leading Japanese manufacturer— suddenly develops a 400 mm crack right through its main frame plate.

For the plant managers, this wasn't just an equipment malfunction; it was an absolute emergency. Replacing a frame of this scale takes months and costs a fortune. That is when they called RA Power Solutions.

Getting Down to Business on Site

Our engineering team headed straight to the plant during a scheduled shutdown to take a closer look. Before we could fix anything, we had to see the true extent of the damage:

  • The plant team stripped away all the parts around the trouble spot.

  • We used chemicals to completely scrub off layers of paint and red oxide.

  • We ran a hardness test on the material.

  • Finally, we performed a magnetic particle inspection (MPI).

The MPI confirmed our worst fears: a horizontal crack measuring 400 mm long running completely through the 40 mm thick frame plate. This press was the backbone of their production line, and it needed a heavy-duty fix, fast.


  Picture Showing Crack in Press Mainframe 


Metal Stitching Under Process 

Why We Chose Metal Stitching Over Welding

When you are dealing with a 3500-ton press, welding is a risky gamble. Heat from welding can warp heavy cast structures and introduce dangerous residual stresses.

Instead, we relied on our decades of experience with the metal stitching and metal locking process. Because it is a cold repair method, zero heat is generated, meaning the original metallurgical properties of the press frame remain completely undisturbed.


Crack having a Length of 320 + 80 mm 


Metal Stitching Under Process 

How We Fixed It Step-by-Step:

Stopping the Spread: We drilled holes right at the extreme ends of the crack to dead-stop it from spreading any further.

  • Cutting the Slots: We cut 6 rows of slots (28 mm deep) across the crack path to house our high-strength locks.

  • Locking It In: We fitted 18 L-30 locks total—6 on the surface and 12 at the bottom.

  • Stitching the Seam: We drilled a series of overlapping holes right along the crack line, inserting precision stitching pins. Each pin overlaps the next to restore full rigidity and lock the casting back together.

  • The Finishing Touch: Everything was ground down completely flush with the surface.


     Press Crack Repair by Metal Locking Process       


Cross Stitching of Crack 

Back in Action

Once we finished the metal locking and cross-stitching, the press was reassembled and put back to work. Today, it is running smoothly and performing right back at full capacity, saving our client weeks of agonizing downtime and heavy replacement costs.

For 47+ years, RA Power Solutions has traveled the world repairing heavy cast iron, steel, aluminum, and bronze components that others wrote off as scrap. When heavy industry breaks down, we bring it back to life.


Press Crack Repair By Metal Locking 


    Finishing of Crack Area After Metal Stitching

Got a cracked component or heavy machinery issue? Let’s talk.

Email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com

Call us: +91 9582647131 / +91 9810012383

“We also have available engine crankpin bearings in our stock.” For more information, visit now: https://rebabbittingbearing.com/ 


We provide crankshaft grinding, in-situ crankshaft grinding, onsite crankpin polishing, damaged engine repair, and worldwide crankpin repair services, covering major industries and engine applications across SAUDI ARABIA, UNITED ARAB EMIRATES, QATAR, KUWAIT, OMAN, and Bahrain.

Source URL: https://rapowersolutions.com/BlogDetails.aspx?blogname=crack-repair-of-a-press-frame-3500-ton-capacity
Watch Our YouTube Video: https://www.youtube.com/channel/UCxcP2Jc6DGFdpBokIcxVyBg


Location: 411, 4th Floor, Arcadia, South City II, Sector 49, Gurugram, Haryana 122018, India

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